UNIT: I Introduction

Computers in Industrial Manufacturing

• Used for automation, monitoring, and optimization of processes.

• Improve precision, efficiency, and reduce human error.

Product Cycle

• Concept Design → Prototype Development → Production Planning →

CAD/CAM Hardware

• CAD (Computer-Aided Design): Used for creating precise engineering drawings.

• CAM (Computer-Aided Manufacturing): Used for controlling machine tools based on

Basic Structure of a Computer

• CPU (Central Processing Unit): The brain of the computer, processes instructions.

• Memory: Stores data temporarily or permanently.

Memory Types

• RAM (Random Access Memory): Temporary memory for active processes.

• ROM (Read-Only Memory): Stores essential system instructions.

• Cache Memory: High-speed memory for quick access to frequently used data.

• Secondary Storage: Hard drives, SSDs, and external storage devices.

Input Devices

• Keyboard, mouse, scanner, touch screen, joystick.

Display Devices

• LCD, LED, OLED screens for visual output.

Hard Copy Devices

• Printers and plotters for producing physical copies of digital designs.

Storage Devices

• Hard drives (HDD, SSD), USB drives, cloud storage.

Computer Graphics
Raster Scan Graphics

• Images made up of pixels stored in a frame buffer.

• Used in screens and digital displays.

Coordinate Systems

• 2D Cartesian (X, Y coordinates) & 3D Cartesian (X, Y, Z coordinates).

• Used for graphical transformations and modelling.

Database Structures for Geometric Modeling

• Wireframe Models: Basic skeletal representation.

• Surface Models: Adds surface details.

• Solid Models: Includes volume properties for real-world applications.

Transformation of Geometry

• Translation: Moving objects.

• Scaling: Changing size.

• Rotation: Spinning objects around an axis.

3D Transformations

• Extension of 2D transformations into 3D space.

• Includes perspective projections and depth calculations.

Mathematics of Projection

• Orthographic Projection: Parallel projection used in technical drawings.

• Perspective Projection: Simulates depth for realism.

Clipping

• Removes parts of graphics outside a defined viewing area.

Hidden Line/Surface Removal

• Ensures only visible parts of objects are displayed.

Shading

• Adds realism by simulating light interaction with surfaces.

Requirements

• Accuracy, flexibility, ease of modification.

• Compatibility with CAD/CAM systems.

Geometric Models

• Wireframe Models: Represent objects using edges and vertices.

• Surface Models: Define surfaces without internal details.

• Solid Models: Complete representation including volume and physical properties.

Geometric Construction Models

• Primitive-Based Modeling: Uses basic shapes like cubes and cylinders.

• Boundary Representation (B-rep): Defines object boundaries.

• Constructive Solid Geometry (CSG): Combines basic shapes using operations like
union and subtraction.

Curve Representation Methods

• Analytic Curves: Lines, circles, conic sections defined by equations.

• Synthetic Curves: Bezier curves, B-splines for smooth transitions.

Surface Representation Methods

• Parametric Surfaces: Defined by mathematical equations.

• Polygonal Surfaces: Approximates complex shapes using polygons.

• Spline Surfaces: Provides smooth transitions.

Modeling Facilities Desired

• User-friendly Interface: Easy manipulation.

• Data Storage & Retrieval: Efficient processing.

• Integration with CAD/CAM: Compatibility for design and manufacturing.

Group Technology (GT)

Part Families

• Grouping similar parts based on design or manufacturing attributes.

• Assigns codes based on geometric and functional features.

• Helps in standardization and process optimization.

Features of Parts Classification & Coding Systems

• Hierarchical Coding: Groups parts in categories.

• Attribute-Based Coding: Uses features like size, shape, material.

• Hybrid Coding: Combination of multiple classification methods.

Production Flow Analysis

• Studies material movement for efficiency.

• Helps in identifying bottlenecks and optimizing workflow.

Cellular Manufacturing

• Organizes machines into cells based on part similarities.

• Reduces lead time and increases flexibility.

Computer-Aided Process Planning (CAPP)

Benefits of CAPP

• Improves efficiency and standardization.

• Reduces planning time and human errors.

• Integrates with CAD/CAM for seamless operation.

Approaches of CAPP

• Retrieval Type: Uses predefined plans for similar parts.

• Generative Type: Dynamically creates new plans using AI and rules.

Implementation Techniques

• Variant Approach: Selects plans from a library.

• Knowledge-Based Approach: Uses decision rules for dynamic planning.

Computer-Aided Quality Control (CAQC)

Inspection and Testing

• Ensures product quality and compliance with standards.

• Can be manual, automated, or AI-driven for precision.

Coordinate Measuring Machine (CMM)

• Uses probes to measure geometric dimensions of objects.

• Provides high-accuracy 3D measurements for quality control.

Non-Contact Inspection Methods

• Laser Scanning: Captures detailed surface data.

• Ultrasonic Inspection: Detects internal flaws using sound waves.

• Vision Systems: Uses cameras for automated defect detection.

Integration of CAQC with CAD/CAM

• Links design, manufacturing, and quality control.

• Improves accuracy and reduces rework by ensuring specifications are met.

Computer Numerical Control (CNC)

Fundamentals of NC (Numerical Control)

• Automatically controls machine tools using programmed instructions.

• Replaces manual operations with precision automation.

Basic Components of an NC System

• Controller: Processes and executes programs.

• Actuators: Drive machine movements.

• Sensors: Provide feedback for adjustments.

Motion Control Systems

• Open-Loop Control: No feedback, relies on preset instructions.

• Closed-Loop Control: Uses sensors for real-time adjustments.

NC Positioning Systems
 • Point-to-Point Positioning: Moves tool to a fixed location.

• Continuous Path Control: Allows for smooth, complex movements.

Advantages & Disadvantages of NC

Advantages:

• High precision and repeatability.

• Reduces manual labor and errors.

• Ideal for complex shapes and mass production.

Disadvantages:

• High initial setup cost.

• Requires specialized programming and maintenance.

CNC (Computer Numerical Control)

Features of CNC

• Advanced automation with computer integration.

• Capable of complex multi-axis machining.

• Provides real-time monitoring and adjustments.

Machine Tool Control Unit

• Central system managing tool movements.

• Ensures precision in cutting, drilling, and shaping.

CNC Software

• Controls machine operations based on preloaded programs.

• Supports simulation and optimization for better efficiency.

Direct Numerical Control (DNC)

Distinction from CNC

• CNC: Each machine has an independent processor.

• DNC: Centralized system controlling multiple CNC machines.

Direct vs Distributed NC

• Direct NC: Machines receive instructions directly from a central computer.

• Distributed NC: Decentralized control with local processing at each machine.

Part Program Fundamentals

• CNC part program is a set of instructions for machine tool operations.

• Written using standard codes (G-code, M-code).

• Controls tool movement, speed, and operations.

Manual Part Program Methods

• Written manually without computer-generated assistance.

• Requires knowledge of machining operations and CNC codes.

• Used for simple or customized machining tasks.

Preparatory Functions (G-Codes)

• Defines machine movement and operation.

• Examples:

• G00 – Rapid movement.

• G01 – Linear interpolation.

• G02/G03 – Circular interpolation (CW/CCW).

• G28 – Return to home position.

Miscellaneous Functions (M-Codes)

• Controls auxiliary machine operations.

• Examples:

• M03/M04 – Spindle rotation (CW/CCW).

• M06 – Tool change.

• M08/M09 – Coolant ON/OFF.

Tool Length Compensation

• Adjusts tool position considering tool length.

• Prevents errors due to tool variations.

• Example: G43 – Tool length compensation.

Canned Cycles
 • Pre-programmed sequences for repetitive machining.

• Common canned cycles:

• G81 – Drilling cycle.

• G83 – Deep hole drilling.

• G84 – Tapping cycle.

Cutter Radius Compensation

• Adjusts tool path considering tool radius.

• Ensures accuracy in contour machining.

• Example: G41/G42 – Cutter compensation left/right.

Tool Nose Radius Compensation

• Accounts for tool nose radius in turning operations.

• Improves precision in machining curved surfaces.

Manual Part Programming for CNC Turning & Machining Centers

• Involves writing G-code manually for different CNC controllers.

• Fanuc Controllers:

• Follow standardized G/M codes.

• Used in lathe and milling machines.

Advanced Part Programming Methods

Looping & Jumping

• Repeats instructions for efficiency.

• Example:

• Loop command reduces code repetition.

• Jump command moves to another section in the program.

Subroutines

• Saves reusable code blocks for frequent operations.

• Example: M98 – Call subroutine.

Mirror Imaging

• Duplicates part geometry for symmetrical machining.

Fundamentals of Computer-Aided Part Programming

• Uses CAD/CAM software to generate CNC programs.

• Reduces manual coding errors.

• Enhances precision and automation.

UNIT - 5 Automation
Automation

Anatomy & Configuration of a Robot

• Major Components:

o Manipulator: Mechanical arm for movement.

o End-Effector: Tool attached for specific tasks.

o Actuators: Motors driving movement.

o Sensors: Provide feedback for precision.

o Controller: Processes instructions and executes motions.

• Configuration Types:

• Cartesian: Linear XYZ movements.

• Cylindrical: Rotational motion with vertical movement.

• SCARA: Horizontal movement for assembly tasks.

• Articulated: Multiple joints for flexibility.

• Parallel: Multiple actuators for high-speed precision.

Characteristics of Robots

• Degrees of Freedom (DOF): Number of independent movements.

• Payload Capacity: Maximum weight a robot can handle.

• Repeatability & Accuracy: Precision of repeated operations.

• Speed & Motion Control: Determines operational efficiency.

Grippers

• Mechanical Grippers: Uses fingers to grip objects.

• Vacuum Grippers: Suction-based gripping.

• Adhesive Grippers: Uses sticky surfaces for handling delicate items.

Applications of Robots in Manufacturing

• Material Handling: Sorting and transferring objects.

• Assembly: Precision joining of parts.

• Welding: Automated high-speed welding.

• Painting & Coating: Uniform surface finishing.

• Quality Inspection: Vision-based defect detection.

Robot Programming Languages

• VAL: Used for PUMA robots.

• RAPID: ABB robot programming.

• KUKA KRL: Specific to KUKA robots.

• Fanuc TP: Used in industrial robotics.

• Python & ROS: Common in modern robotic systems.

Computer Integrated Manufacturing (CIM)

Elements of CIM

• CAD: Design automation.

• CAM: Machine automation.

• CAPP: Process planning automation.

• Robotics & Automation: Production optimization.

• Database Management: Organizes manufacturing data.

Virtual Reality (VR)

• Definition: Simulated digital environment.

• Uses in CIM:

• Training workers in machine operations.

• Simulating production lines before implementation.

Augmented Reality (AR)

• Definition: Digital overlays on real-world environments.

• Enhancing maintenance by overlaying machine data.

• Improving assembly instructions with real-time guidance.

Artificial Intelligence (AI) in CIM

• Predictive Maintenance: AI predicts equipment failures.

• Process Optimization: AI improves efficiency.

• Quality Control: AI detects defects using vision systems.

Expert Systems in CIM

• Definition: AI systems that mimic human decision-making.

• Applications:

• Automated fault diagnosis.

• Decision support in production.

• Optimized scheduling and resource allocation.